Solar powered system with grid backup

ABSTRACT

A system includes a solar power subsystem that receives power from one or more solar power arrays. A storage control subsystem is coupled to the solar power subsystem to charge a battery from the power received by the solar power subsystem. A grid power control subsystem having an AC to DC converter receives power from a power grid and provides DC voltage to the storage control subsystem. A balance of system control system controls the amount of power received from the power grid as a function of a load, battery charge and received power by the solar power subsystem. The solar array and battery may be sized to provide sufficient power under normal operating conditions, with power being drawn from the grid during abnormal operation conditions.

RELATED APPLICATIONS

This application is a Continuation of U.S. application Ser.No.12/564,623, filed on Sep. 22, 2009, which is incorporated herein byreference in its entirety.

BACKGROUND

Solar cells can eliminate the need for grid-tied electrical power. Theamount of expensive solar material may be overdesigned to handle allboundary conditions, such as fifteen straight days of heavy overcastweather, to ensure reliability. The additional solar material needed tohandle the boundary conditions may be too expensive and lead to adecision not to use a solar powered solution.

In some solar cell based solutions, the solar cells are coupled to thegrid to feed power back into the grid when more power is produced thanneeded. Complex and expensive switching circuitry may be needed todisconnect the solar cells from the grid when excess power is not beingproduced.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a control system for solar powered devicesaccording to an example embodiment.

FIG. 2 is a detailed block diagram illustrating components of thecontrol system of FIG. 1.

FIG. 3 is a block diagram of a grid power control system according to anexample embodiment.

FIG. 4 is a block diagram of a storage control system according to anexample embodiment.

FIG. 5 is a block diagram of a photo voltaic control system according toan example embodiment.

FIG. 6 is a block diagram of an application control system according toan example embodiment.

FIG. 7 is a block diagram of a balance of system control systemaccording to an example embodiment.

FIG. 8 is a block diagram of a computer system to implement one or moresystems and methods according to an example embodiment.

FIG. 9 is a graph illustrating a modified lighting profile showing wattsprovided as a function of time of day.

DETAILED DESCRIPTION

In the following description, reference is made to the accompanyingdrawings that form a part hereof, and in which is shown by way ofillustration specific embodiments which may be practiced. Theseembodiments are described in sufficient detail to enable those skilledin the art to practice the invention, and it is to be understood thatother embodiments may be utilized and that structural, logical andelectrical changes may be made without departing from the scope of thepresent invention. The following description of example embodiments is,therefore, not to be taken in a limited sense, and the scope of thepresent invention is defined by the appended claims.

The functions or algorithms described herein may be implemented insoftware or a combination of software and human implemented proceduresin one embodiment. The software may consist of computer executableinstructions stored on computer readable media such as memory or othertype of storage devices. Further, such functions correspond to modules,which are software, hardware, firmware or any combination thereof.Multiple functions may be performed in one or more modules as desired,and the embodiments described are merely examples. The software may beexecuted on a digital signal processor, ASIC, microprocessor, or othertype of processor operating on a computer system, such as a personalcomputer, server or other computer system.

A solar-electric hybrid system includes a solar powered system with abackup grid connection. The hybrid system may result in much reducedupfront cost compared to either grid only (conventional) solutions orsolar only solutions. Operating costs may be minimized compared to gridonly solutions. Upfront costs may be minimal compared to a solar-onlysystem, as additional costly solar material is not needed to coveroccasional adverse solar power conditions. The use of a grid-connectedbackup facilitates use of enough solar material to provide power duringnormal operating conditions without using additional solar material toprovide sufficient power during abnormal solar power conditions.Operating costs may be reduced because of the decreased pull from thegrid due to solar power generated by the system and decreased need forbattery maintenance, as the batteries may not be relied on as much as inprior systems. The power may be taken from the grid in case ofexceptional conditions in some embodiments.

An advanced electronic control system may be referred to as a selfpowered device interface (SPDI) as shown generally at 100 in FIG. 1. Thesystem 100 may be used to control solar power collection, batterycharging and discharging, an application receiving power, and a gridconnection. In one embodiment, system 100 consists of multiple systemsthat may be referred to as subsystems, that control various aspects ofpower management. In further embodiments, different subsystems may beconsolidated into one or more systems, or may be broken into furthersubsystems. The subsystems may be implemented in hardware orcombinations of hardware running software programs in variousembodiments.

Control system 100 may include a grid power control subsystem (GPCS) 110that manages access to power from an electrical grid. AC power comes inthrough the interface of the system and is converted to DC and used asneeded. Only one connection to the grid is included in one embodiment.In further embodiments, multiple grid connections may be used ifdesired.

A storage control subsystem (SCS) 120 controls the electricity thatcomes from the GPCS 110 and stores it in one or more battery banks untilcalled for by an application control system 130 that controls powerprovided to one or more load devices.

A photo voltaic control subsystem (PVCS) 140 manages electricity comingfrom a solar array. The electricity from the solar array is routed tothe SCS 120. More than one array may be used in various embodiments. ThePVCS 140 manages the electricity from all of arrays.

An application control subsystem (ACS) 130 may control power provided toanything that uses power, such as a street light, a electrical consumerappliance like a radio or a commercial device like a Wi-Fi repeater.Multiple applications may be connected to the system, and the ACS 130controls the power to each, and manages a priority for each application.

A balance of system (BOS) control subsystem (BCS) 150 acts as the systembrain and interpreter between the other subsystems. It also provides theuser interface for system programming and system performanceinformation.

Further detail of a self powered device interface is shown generally at200 in FIG. 2. Self powered device interface 200 in one embodiment is auniversally extensible access point for intelligently interfacingbetween the PV power generation, power pull from the grid, power storageand distribution to an application. It controls the different systemcomponents: PV cells, batteries and charge controllers, and providesstandard interfaces to interact with the system and provide systemperformance information.

A photo voltaic control subsystem 210 collects and conditions power froma photovoltaic source, such as a photovoltaic array 212 via an inputport 214. Input port 214 is coupled to a photo voltaic line regulator216, that makes power from the array 212 available to the system 200 viapower distribution lines including a photovoltaic line 217, load line218 and ground 219. In one embodiment, ground line 219 acts to groundall subsystems.

A storage control subsystem 220 conditions collected power at 222 via aninput port 223 for storage into a battery bank 224. A load lineregulator 226 receives control signals from the system controller 242 tocontrol operation of the storage control subsystem 220.

An application control subsystem 230 acts as a mechanical and electricalinterface point between applications and stored power and provides loadmanagement capabilities via a load controller 232. In one embodiment,the load controller 232 is coupled to an input port 234, which may becoupled to one or more loads 236 via one or more adapters 238. Adaptersmay be application specific, providing the power profile required by theapplication (12 VDC vs. 6 VDC, for example).

A balance of system control subsystem 240 controls the source of power(either batteries from the SCS or grid from the GCS), sends and receivescontrol data to run the numerous safety and intelligence aspects of thesystem including fault protection, Device Priority Protocol (DPP), andothers. These functions are performed via a system controller 242, whichis coupled to a software interface 244. Software interface 244 mayprovide the above functions in software form, and in addition mayprovide user interfaces for changing the manner in which power may bebalanced in the system 200. Balance of system control subsystem 240 maybe coupled to the other subsystems via a control bus as illustrated inFIG. 7, but is not shown so connected here to reduce the complexity ofFIG. 2.

A grid power control subsystem 250 includes an AC to DC converter 252that may be coupled directly to the grid to receive AC power and convertit to DC power. Converter 252 may be coupled to an input port 254, whichis in turn coupled to a hybrid power regulator 256. Hybrid powerregulator 256 in one embodiment, is coupled to both the grid via inputport 254, and to the power distribution lines 217, 218, and 219. Whensufficient power is received via photovoltaic line 217 to charge battery224 or feed directly to the ACS, no grid power need be drawn. At othertimes, when the load from ACS is drawing more current than can beprovided by the battery or PVCS, or when control algorithms indicatethat the battery will be drained of power before the photovoltaic array212 may provide sufficient power again, power may be drawn from the gridto service the load 236.

In one embodiment, the system 200 runs at 24V DC. With the exception ofthe AC/DC converter 252, all components and connections may be DC power.

FIG. 3 provides further detail of the grid power control system 250, andit contains reference numbers consistent with FIG. 2. Grid power controlsystem 250 controls the power if and when it needs to be tapped from theelectrical grid. Power comes in as AC and gets converted to DC. It isprovided to the system when the balance of system control subsystem 240requests it.

At the connection to the grid, a UL certified transformer 252 may beused to convert the grid power to 24 VDC. From that point on, system 200may be run at 24 VDC. All the components and connection are DC power inone embodiment. Only one connection to the grid is supported in oneembodiment, and there is no connection feeding power back into the grid.

FIG. 4 provides further detail of the storage control subsystem 220.Storage control system 220 in one embodiment conditions and storeselectrical energy provided by the photovoltaic control system 210 forlater use. In one embodiment, a physical manifestation of storagecontrol system 220 may accommodate multiple battery banks as illustratedat 224 and 424 with different numbers of batteries and/or differentbattery chemistries. The battery banks are each coupled via respectiveinput ports 223 and 423. While two are illustrated, many more may beprovided in further embodiments. The stored electrical energy may bedelivered to the application control subsystem 230 via the load lineregulator 226.

The storage control subsystem 220 in one embodiment supports multiplebattery ports for modularity and expansibility of storage capacity.Multiple battery chemistries can be used. So long as differing batterychemistries are attached to different input ports, the system 220 willbe able to optimize charging to batteries on a case by case basis. Thestorage control subsystem 220 may optimize the charge profiles of thebattery banks for each individual battery and chemistry. This can beoptimized for maximum charge speed, maximum battery life or a balancebetween the two extremes. The storage control subsystem 220 may alsomonitor the battery temperature to allow for maximum battery chargingrates while maintaining safety and battery health. The storage controlsubsystem 220 also can include a battery heater for cold weatherconditions. The storage control subsystem 220 can handle multiplebattery input voltages.

The photovoltaic control subsystem 210, shown in further detail in FIG.5, enables the system 200 to flexibly connect with multiple photovoltaicarrays 212, 512, 516 of varying electrical output characteristics viacorresponding input ports 214, 514, and 518. Photovoltaic control system210 actively controls and optimizes the photovoltaic array power outputspecific to the individual arrays over varying environmental conditions.In addition, it converts the varying electrical power inputs to amanageable system voltage via regulator 216.

Multiple photovoltaic arrays 212, 512, 516 and more, can be integratedinto the subsystem, each with their own input port 214, 514, 518 withstandardized mechanical and electrical interfaces through which solararrays are attached. The photovoltaic control subsystem 210 may be usedto ensure that the maximum power is generated by each solar array andthat no one array shadows or degrades the system. MPPT (Maximum PowerPoint Tracking) may be used to manage different insulation values,environmental conditions and solar panel technology. This subsystem mayalso manage sun tracking for increased system efficiency. This reducesthe losses and costs associated with conditioning the photovoltaicinputs to the system.

In further embodiments, the photovoltaic control subsystem may bereferred to as a solar power subsystem, as any means of obtaining powerfrom the sun may be utilized in addition to photovoltaic means. Somefurther examples of arrays include arrays of minors to heat a boiler toproduce power, thermocouple type solar arrays, as well as other devicesthat can produce power from sunlight.

Application control subsystem 230 is shown in further detail in FIG. 6.Application control subsystem 230 provides the interface to drivemultiple applications or loads 236, 636, 648. Each application or loadis coupled to the load controller 232 via respective input ports 234,634, 644 and adapters 238, 638, 648. A Device Priority Protocol (DPP)technology prioritizes the applications for power management purposes.DPP is a method of defining the relative priorities of multipleapplications, and a set of rules to provide power to those applications.If the system power needs to be rationed, the relative priorities andrules may result in lower priority applications being turned off, orsupplied a reduced power. Application control subsystem 230 detects andswitches applications on or off or modifies their power or performanceusing an Intelligent Load Application Interface (ILAI) in conjunctionwith the DPP. In various embodiments, an adapter may or may not be used,but will be provided if the electrical (Voltage/Current) requirementsfor an application/load are different than that provided by the platformapplication port.

The application control subsystem 230 uses Device Priority Protocol inone embodiment to prioritize applications for power management purposes.The Intelligent Load Application Interface Technology allows thesubsystem to provide variable power levels (on, off, or a state inbetween) to applications based on DPP. It also allows applicationdisconnect when a failure is detected.

The balance of system control subsystem 240 is shown in further detailin FIG. 7. The balance of system control subsystem 240 acts as thesystem 200 brain. Because of the extensibility and the intelligencebuilt into the system 200 architecture, each subsystem may include verysophisticated controlling capability. Balance of system controlsubsystem 240 communicates with all the other subsystems, via thecontroller components 222, 216, 256, 226, and 232, and receivesinformation from them via a control line 710 that is coupled to systemcontroller 242. It also sends commands to all the different subsystems.Balance of system control subsystem 240 contains the programming for theentire system. This subsystem 240 holds the programming and provides auser interface via software interface 244 for control and status data.

The balance of system control subsystem 240 contains the systemintelligence. It manages the device priority protocol which allowssubsystems to prioritize the different applications for power managementpurposes. It contains the Intelligent Load Application InterfaceTechnology, which allows the subsystem to provide variable power levelsto applications based on DPP (on, off, or a state in between such asrunning at 50% power). Balance of system control subsystem 240 performssystem monitoring on battery charge level, power generation, and powerconsumption level (all both historical and current).

Balance of system control subsystem 240 contains the user interface.This allows system configurability, allowing the user to perform setupand user customization, power management customization, device priorityprotocol, intelligent load application interface. The balance of systemcontrol subsystem 240 also provides a graphical output of the systemstatus to user. In one embodiment, balance of system control subsystem240 manages the communication between the subsystems and to the externaluser interface: GUI, keypad, touch screen LCD panel, wired USBconnection or a wireless connection.

Balance of system control subsystem 240 manages fault control, thecontrol of the maximum power threshold for the photovoltaic line 218 andthe load line and controls the maximum battery discharge levels toprotect the battery banks from damage.

In one embodiment, the subsystems may be implemented using multiple8-bit digital/mixed signal microcontrollers with a built in real-timeclock. Multiple control functions are possible. For example, for alighting application, the following controls are possible:

The control mechanism allows for dusk to dawn control. A light sensormay be used to provide the control mechanism with light levels on whichto base control. In further embodiments, the real time clock may includea calendar function and a sunrise/sunset table for use in determiningappropriate times for dusk and dawn on which to control.

The light level can be modified based on detection of movement such asby use of motion sensing devices.

The light level can be reduced if battery charge is low based on one ormore thresholds and various other controls, such as time of day. Usercontrols may also be provided to allow overriding of the light levelreduction.

The light can vary throughout the night, brighter before midnight,dimmer after midnight.

In one embodiment, photovoltaic line 217, acts as the power input busfor the system. The photovoltaic control subsystem 210 sends power viathe photovoltaic line regulator 216 to the batteries through thephotovoltaic line 217.

Load line 218 in one embodiment acts as the power output bus for thesystem 200. Battery power is transferred to the load line, via the loadline regulator 226 in the storage control subsystem 220. When requestedby the storage control subsystem 220, grid power is transferred to theload line from the grid power control subsystem 250 via the hybrid powerregulator 256. Applications are fed power from the load line 218, viathe load controller or controllers 232 in the application controlsubsystem 230.

All subsystems communicate with the balance of system control subsystem240 through the control line. The balance of system control system 240sends and receives information and commands via the control line. Thebalance of system control system 240 is programmed and sends out systemstatus information via the control line.

A block diagram of a computer system or microcontroller that executesprogramming for one of more subsystems described above is shown in FIG.8. A general computing device in the form of a computer 810, may includea processing unit 802, memory 804, removable storage 812, andnon-removable storage 814. Memory 804 may include volatile memory 806and non-volatile memory 808. Computer 810 may include—or have access toa computing environment that includes a variety of computer-readablemedia, such as volatile memory 806 and non-volatile memory 808,removable storage 812 and non-removable storage 814. Computer storageincludes random access memory (RAM), read only memory (ROM), erasableprogrammable read-only memory (EPROM) & electrically erasableprogrammable read-only memory (EEPROM), flash memory or other memorytechnologies, compact disc read-only memory (CD ROM), Digital VersatileDisks (DVD) or other optical disk storage, magnetic cassettes, magnetictape, magnetic disk storage or other magnetic storage devices, or anyother medium capable of storing computer-readable instructions. Computer810 may include or have access to a computing environment that includesinput 816, output 818, and a communication connection 820. The computermay operate in a networked environment using a communication connectionto connect to one or more remote computers. The remote computer mayinclude a personal computer (PC), server, router, network PC, a peerdevice or other common network node, or the like. The communicationconnection may include a Local Area Network (LAN), a Wide Area Network(WAN) or other networks.

Computer-readable instructions stored on a computer-readable medium areexecutable by the processing unit 802 of the computer 810. A hard drive,CD-ROM, and RAM are some examples of articles including acomputer-readable medium.

Solar cells can eliminate the need for grid-tied electrical power. Butprior to the introduction of this solar-electric hybrid solution, theamount of expensive solar material had to be overdesigned to handle allboundary conditions (for example, 15 straight days of heavy overcastweather) and ensure system reliability. Using the hybrid technology, theamount of solar material can be conservatively sized to provide enoughelectricity for average weather patterns. Edge cases may be handled bytaking power from the grid. This results in a significant cost savingsover a solar-only option by reducing the amount of solar materialrequired.

One example control system load includes a parking lot light. The lightneeds to be lit from dusk until 1:00 am in one embodiment. The light maybe fitted with solar material, in the form of polycrystalline siliconphotovoltaic cells mounted to the top of the light.

The amount of surface area on the lantern top is approximately 0.13square meters. For this particular location, the sun is expected toprovide on average 6.77 peak sun hours per day. The average amount ofenergy coming from the sun, available to power the light on a dailybasis is calculated as follows:

(amount of solar material)×(efficiency of solar material)×(amount ofenergy coming from the sun)×(losses due to less than optimal solarmaterial positioning)=(amount of energy available to power the lantern)

For this example the average amount of energy coming from the sun iscalculated as:

0.13 sq m of solar material×13% efficiency of solar panels×6,770 watthours/sq meter×45%=51 watt-hours

Today's most efficient lighting solutions use LEDs (light emittingdiodes. Power to the LEDs can be modulated from a level of 3 Watts to 30Watts. The different power levels result in corresponding changes in anillumination level.

If the LEDs were run at 8 watts, the power usage throughout the year isexpected to be as shown in Table 1:

TABLE 1 Power Required to run a light during different times of yearHours Total Watts Time of Until Total Watts Expected Month Sunset 1:00am Required from Sun December 4:59 PM 8.00 64.00 51 March 7:17 PM 5.7245.76 51 June 8:25 PM 4.58 36.64 51 September 7:17 PM 5.72 45.76 51

If run at 8 watts, the light can run during most of the year on onlysolar power. However, during the winter months, with their reducedsunlight hours and increased need for illumination, the amount of solarmaterial is not sufficient to run the light with only solar power.

In one embodiment, weather may be taken into account. The insolationnumber sited earlier (6.77 peak sun hours per day) is just an average.If the weather is abnormally overcast, power from the sun will bereduced and the light may also not perform as necessary.

To mitigate these factors, power to the light may be programmed toconserve energy during periods when the battery power is lacking. Onepossible option is to decrease the wattage (and the illumination levelduring the night.

An example of a power-savings usage profile is shown in FIG. 9, which isa graph illustrating a modified lighting profile showing watts providedas a function of time of day. As shown in FIG. 9, a constant 8 wattlevel of illumination identified at 910 may be desired. However, ifneeded, a modified lighting profile identified at 915 may be used toreduce the power in a predetermined manner. In one embodiment, the powermay be reduced in steps as the evening hours progress, so that by 1 AM,the power level is one-half of the normal level. Further profiles may beused and modified based on the needs of the load. While a lighting loadis shown, there are many other types of loads that may be controlled inthe same manner.

However, even if the lighting profile is modified to draw less powerfrom the battery, perhaps in the winter months, a snow storm mightdarken the sky for several days. Such a storm would reduce the solarpower generated and result in depletion of the battery.

To mitigate the effects of a snow storm or other factors, the light canbe lit using a solar/electric hybrid system as described above. Thesystem may function like the solar-only option, except with theinclusion of a backup grid-tied power connection, allowing for increasedillumination levels for shaded locations, exceptionally overcastperiods, or when it is desired that the light shine very brightly.

A grid backup allows for a smaller, less expensive battery, and reducesmaintenance costs. However, it also requires a transformer, whichincreases the cost.

Operating costs may be increased slightly compared to the solar onlyoption, since during exceptional times, electricity is being taken fromthe grid. Compared to a traditional grid-tied light, operating costs aresignificantly reduced because electricity is only needed duringextraordinary circumstances.

In this example, using 24 1-Watt LEDs, the system would need a 12 Volt,10 amp.hour battery, and 0.13 sq. meters of polycrystalline siliconphotovoltaic cells.

The Abstract is provided to comply with 37 C.F.R. §1.72(b) to allow thereader to quickly ascertain the nature and gist of the technicaldisclosure. The Abstract is submitted with the understanding that itwill not be used to limit the scope or meaning of the claims.

1. A method comprising: receiving power from a solar array; using thereceived power from the solar array to charge a battery; applying powerfrom the battery to power multiple loads; monitoring power consumed byloads; and supplying a reduced power to selected loads as a function ofpower received from the solar array and available battery power.
 2. Themethod of claim 1 and further comprising: determining a powerrequirement to power a load in normal operating conditions; anddetermining sizes for the solar array and the battery to providesufficient power to the load during normal operating conditions.
 3. Themethod of claim 2 wherein power is drawn from the grid during abnormaloperating conditions.
 4. The method of claim 3 wherein abnormaloperating conditions are defined as within selected boundary operatingconditions.
 5. The method of claim 4 wherein the size of the solar arrayis no larger than that needed to supply sufficient power to the loadwithin the selected boundary operating conditions.
 6. The method ofclaim 1 and further comprising: monitoring a battery drain rate;determining expected power to be received from the solar array;determining if the battery has sufficient power to power the loads priorto the solar array providing power to sufficiently power the loads atreduced power and recharge the battery; and drawing power from the gridif sufficient power from the solar array is not expected.
 7. The methodof claim 1 and further comprising turning off selected loads wheninsufficient power from the batter and solar array is available.
 8. Themethod of claim 1 wherein the reduced power is provided to selectedloads as a function of a predetermined priority for each load.
 9. Themethod of claim 1 wherein power is reduced as a function of time of day.10. The method of claim 1 wherein the battery is charged in accordancewith a charge profile for the battery dependent on battery size andchemistry.
 11. A method comprising: receiving power from a solar array;using the received power from the solar array to charge a battery;applying power from the battery to power multiple loads; monitoring abattery drain rate; determining expected power to be received from thesolar array; determining if the battery has sufficient available powerto power the loads prior to the solar array providing power tosufficiently power the loads and recharge the battery; and supplying areduced power to selected loads as a function of power received from thesolar array and available battery power.
 12. A method comprising:determining total power requirements for multiple loads for operationduring normal operating conditions; determining sizes for a solar arrayand a battery to provide sufficient power to the loads during normaloperating conditions; selecting a controller to control providing powerto the loads and charging battery such that power is drawn from a gridconnection during operation outside normal operating conditions;monitoring power from the load, wherein the load comprises multipleloads; and supplying a reduced power to selected loads as a function ofpower received from the solar array and available battery power.
 13. Asystem comprising: a solar power subsystem that receives power from oneor more solar power arrays; a storage control subsystem coupled to thesolar power subsystem to charge a battery from the power received by thesolar power subsystem; a battery monitor to determine if the battery hassufficient power to power multiple loads; and an application controlsubsystem to monitor power needed by the loads, and to provide a reducedpower to selected loads as a function of power received from the solararray and available battery power.
 14. The system of claim 13 whereinthe solar power arrays include photovoltaic arrays.
 15. The system ofclaim 13 wherein the solar power arrays have a size limited to providesufficient power under normal operating conditions.
 16. The system ofclaim 13 and further comprising: an application control subsystem tomonitor power needed by the load, and to reduce power provided toselected loads as a function of power received form the solar array andavailable battery power.
 17. The system of claim 16 wherein theapplication control subsystem turns off selected loads when insufficientpower from the battery and solar array is available.
 18. The system ofclaim 16 wherein power is reduced to selected loads as a function of apredetermined priority for each load.
 19. The system of claim 16 whereinpower is reduced as a function of time of day.
 20. The system of claim13 wherein the storage control subsystem comprises multiple batteriesand wherein each battery is charged in accordance with a charge profilefor the battery dependent on battery size and chemistry.